A customer in Washington DC ordered this commemorative sign to honor a colleague in there science lab who is leaving.
This is made of roughly 11′ x 11′ x 1″ sapele wood.
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After a few design iterations, the customer was happy with this graphic.
The background is made of weatherproof 1″ HDU 15 lb. foam and hand carved to look like rustic wood. Two panels were carved to go back to back to make a double sided sign.
The letters were carved out of .5″ acrylic and painted.
Next, layers of color were added to the wood texture. Starting with black, then dry brushing browns over the top to give the illusion of real wood. Rebekah did a great job texturing and painting!
A steel frame was embedded in between the foam sheets for structural support.
Next, everything was glued together with construction adhesive caulk and clamped.
Here are the final pics!
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This customer approached me with their logo and asked to have it made into a 3D sign.
The first step was to design the CNC work paths…
Once all the components are made, we clean them up and start painting.
Once painting is complete, assembly begins, gluing and screwing…
Finished pics!
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This customer sent these pictures of shields. He wanted 4 shields similar to this but with marine images.
This is the design we came up with…
To begin, these were designed and and cut out on the CNC router out of 3/4″ pvc board.
Next, we began the painting process using Modern Masters iron/ rust paint to make them look like old metal.
The shields received 2 coats of Modern Masters iron paint primer… Then 3 coats of iron paint. Then, the fun part, applying the activating spray to start the rust process. This is a shot of the first coat of spray…
After 2 coats…
After about 5 irregular coats and 24 hours of oxidizing we got the results we liked…
The last step is to apply the sealer which stops the oxidation. We applied a 50% water, 50% sealer mix and sprayed it on. It dried with a nice flat finish and looks like real rusted metal. These are going to be inside, but if they were outside, they recommend putting another coat of undiluted sealer. The downside to this is you get a sheen over the rust which takes away the realism.
Lastly, a french cleat and bump outs were attached to the backs of the shields for easy hanging. Here are the finished pics.
Here are a series of videos showing the process…
If you’re interested in trying out this paint, click this link and it will bring you to it’s home on Amazon…
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A couple years ago we had the opportunity to create two signs for the Ron Clark Academy in Atlanta. As a result, the principal of the Bronx Lighthouse Charter School in NYC was visiting the Ron Clark Academy and was inspired by our signs and came back to his school with an idea and he got in touch.
He sent us this concept of the anchor, wheel and his school logo.
We took out the chain and added textures and layers.
Once approved, we began designing all the pieces to cut out on the CNC out of 15 lb. HDU.
After all the pieces were cut out, then the fun could begin in shaping and sculpting and assembling all the pieces.
This was a big sign. 8 ft. wide by 8.5 ft. tall with 4 layers. We had our friends at Welding Works weld up some steel c channel into a frame that was embedded into the back of the anchor that all the layers would be bolted to.
We used hand tools and power tools to shape the parts.
The anchor needed to look like an old rusty surface, so we experimented with different tools to create a pitted surface. The guys arms were getting tired as you can see.
Finally, we could assemble all the pieces and see how it looks!!
Next, it was time to paint and detail!!
We used some epoxy gelcoat and casted these little domes to use as hardware on the iron band.
The design concept was to limit the materials to weathered wood and metals. For the anchor and the metal band, we used Modern Masters iron rust paint. For the lighthouse logo, we used Modern Masters bronze and copper with their green and blue patina sprays. For the old wood, we painted it black first and then dry brushed medium and light toned browns over the black.
Letters were .5″ acrylic laser cut and painted.
We used glue and screws and bolts to put it all together.
Yeah!! We finished on time!!
We built a shallow plywood frame to attach it to for delivery to NYC where the school maintenance will install it.
Another satisfied customer!! This was a really fun sign to make!
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The Ron Clark Academy in Atlanta Georgia has a grand opening of their new building coming up and has ordered a 4′ x 5′ Coat of arms for the school… Here is the design and some pictures of the creative process so far…
Just waiting on the Text to finish being carved and painted and then the whole thing will be glued up and ready to ship! Final pictures to come….
OK! Here are the finished pics!!
Here is a link to Atlanta news. They got some nice shots of our sign!!
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We got our first snow of the winter today!!
Painted and installed!!!
Last post I showed the process of creating these models, molds and fiberglass resin casts. They were then shipped to Danny Powell of Signstar signs in Tampa FL. This was a collaboration project. Here are the pics of what Signstar did with the casts.
After their amazing airbrush job, they installed…
This was a wonderful collaboration with Danny Powell from Signstar in Tampa, Florida. Thank you Town of Indian Shores for trusting us with your 5 new monument signs!
Thank you for looking!
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A recent fiberglass resin cast sign! Custom Sculpture & Sign Company The town of Indian Shores Florida is creating 5 monument signs and we’ve been contracted to create the fiberglass resin Indian and wave forms for the signs. This involves … Continue reading
I have had my eye on this paint product from Modern Masters and gave it a try on a relief carving made out of HDU that I made for a recent project.
First, you apply the metal effects primer…
Then apply the 2 coats of the iron paint…
Then apply several coats of the rust activator spray. The rust increases with each application…
Now you have a rusted metal sculpture!!! (at least the illusion of one) There is one more step I don’t have a picture of and it’s a clear sealer that prevents the iron from oxidizing any more. I am very pleased with this product.
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If you have an idea for a custom sculpture or sign visit the contact page to get in touch!!
This sign was made of 3/4″ thick walnut boards edge glued together to make a sign roughly 16″ x 60″ with carved and painted letters and routed decorative edge, finished with a clear satin.
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